Cantilevered mask for openings in additively manufactured part

Abstract

A mask is provided for an additively manufactured part including a plurality of spaced openings in a surface of the part. The mask is made with the part and includes an attachment ligament configured to integrally couple to the part between the openings in a cantilever fashion. First and second cover members include a proximal ends integrally coupled to the attachment ligament and distal ends extending at least partially over a respective portions of the plurality of openings. A detachment member extends from each of the first and second cover members. The attachment ligament is the sole connection to the part. The mask may have an umbrella shape in cross-section.

Description

BACKGROUND[0001]The disclosure relates generally to post-manufacturing processing of parts and more particularly, to a mask for protecting openings in a surface of an additively manufactured part.[0002]Additive manufacturing (AM) includes a wide variety of processes of producing a part through the successive layering of material rather than the removal of material. As such, additive manufacturing can create complex geometries without the use of any sort of tools, molds or fixtures, and with little or no waste material. Instead of machining parts from solid billets of material, much of which is cut away and discarded, the only material used in additive manufacturing is what is required to shape the component. Accordingly, many industrial parts such as turbine rotor blades are preferably made by additive manufacturing.[0003]Subsequent to formation by additive manufacturing, the parts may be further processed. In one example, the part may be exposed to a shot peening in which the surfa...

AI Technical Summary

Benefits of technology

The solution effectively protects openings during processing while allowing for easy mask removal without cracking the coating or compromising part performance, reducing manufacturing time and complexity.

Problems solved by technology

The removable material blocks the coating from entering the openings, but increases manufacturing time and complexity because the removable material and / or the coating thereover must ultimately be removed.

For example, each opening must have the blocking material removed, which can be time consuming.

Because the coating bridges over the blocking material, removal of the coating can cause extensive cracking in the rest of the coating, e.g., a TBC, that may render the part unusable or require extensive additional processing.

Removal of blocking material after a peening process can be especially challenging where the blocking material is seized with the part's material by the process.

In this latter case, the complexity of the part is increased, and the performance of the part may be sacrificed to accommodate the shielding.

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